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WELCOME TO

Presentation on New Concepts in Supercritical

Turbines

Sanjoy Bhattacharya

Dy. Genl. Manager, BHEL, Hardwar

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HPT IPT LPT

CROSS SECTIONAL ARRANGEMENT OF 500 MW STEAM TURBINE

THREE CYLINDER TURBINE

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Introduction of New Rating SetsMajor Objectives

Bring down equipment cost per MW

Having more Efficient & Reliable product

Utilize available Steam turbine modules

Provide Higher competitiveness

New Rating to compete with Chinese/ New Indian firms

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600MW Steam turbine: Built from proven modules of existing 500 & 250 MW

Orders for 4x600 MW Raigarh-III (Jindal), 2x600 MW Malwa, 2x600 MW each Avantha / Videocon/ Visa Raigarh/ DB Power & 1 x 600 MW Rayalaseema received .

Module Combination• HP: H30-100• IP : M30-63• LP : N30-4x6.3

Salient features:• 4 cylinder turbine (2 LPs)• HP turbine with Extraction connection for 565 HRH Temp• IP turbine suitable for 537/565 0C inlet temp.

OPTIONS1. HP Turbine with Extraction & 565 Deg C HRH Temp 2. HP Turbine without Extraction & 537 Deg C HRH Temp

Orders for 2 sets - N Chennai, 2 sets –JITPL, 1 set -APGENCO & 2 sets Singareni received.

Steam parameters 170 ata / 537 0C/ (537-565) 0C

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600MW Steam Turbine

Design Changes from existing 500 MW sets :

•HP module variant with Extraction• New Flow path in HP, IP & LP Turbines (with Advanced blading)

• Matching modifications in Rotors & Inner Casings

• New Bearing pedestal between 2 LP cylinders

• New design of Cross Around Pipe & its support

• Enhanced governing characteristics

600 MW Sub critical Sets

Steam Turbine

500/ 600 MW SUB CRITICAL CYCLE

WITH 2 HP HEATERS, 3 LP HEATERS

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Introduction of Steam Turbine with supercritical parameters

As the fluid pressure increases, Latent Heat (Enthalpy of Steam –Enthalpy of Water) reduces.

At Critical point it becomes zero.

In physical terms at this pressure water transforms to steam spontaneously.

SUPER CRITICAL STEAM PARAMETERS:

PARAMETERS MORE THAN CRITICAL STATE• STEAM PRESSURE > 221.2 BAR• STEAM TEMPERATURE > 374.15 Deg C

ULTRA SUPERCRITICAL PRESSURE( 300 BAR)

INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg CRESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE

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500 MW 800 MWSubcritical

170 ata / 537 °C / 537 °C

Super Critical247 ata / 565 °C /

593 °C

Imp

rov

em

en

t

4.3 %

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Steam Power plant efficiency increases with increase in steam pressure and temperature.

Power plant Cycles operating above critical pressure (221.2 bar) are classified as Supercritical cycles

With higher cycle efficiency, the supercritical cycle offers the advantage of ‘burn less fuel for the same output’ and lower emission.

Supercritical Cycles

Lesser Pollutants – SOX , NOX & CO2

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IMPROVEMENT IN EFFICIENCY WITH INCREASING INLET PARAMETERS FOR STEAM TURBINES

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PARAMETERS UNIT 500 MW 660 MW 800 MW

MS PRESSURE ATA 170 247 247

MS TEMPERATURE oC 537 565 565

MAIN STEAM FLOW T/HR 1500 1919 2380

REHEAT PRESSURE ATA 40.5 56 60

RH TEMPERATURE oC 537 593 593

FINAL FEED WATER TEMP.

oC 253 290 290

PARAMETERS FOR BHEL STEAM TURBINES

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Typical Supercritical TG Cycle

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REGENERATIVE CYCLE CONFIGURATION

• TWO EXTRACTIONS FROM IPT

• FOUR LP HEATERS

• DEAERATOR

• ONE EXTRATION FROM HPT

• THREE HP HEATERS

• 250% TURBINE DRIVEN BFP

• ONE MOTOR DRIVEN BFP

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STEAM TURBINE MODULE CONFIGURATION

MODULE 500 MW 660 MW 800 MW

HP TURBINE H30-100 H30-100 H30-100

IP TURBINE M30-63 M30-100 M30-100

LP TURBINE N30-2 x 10 N30-2 x 12.5 N30-4 x 8

HP VALVES 2 x FV320 2 xFV250A 2 xFV250A

IP VALVES 2xAV560 2xAV560A 2xAV560A

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660MW Steam turbine: With Supercritical parameters

Order for 2x660 MW Barh- II/ DB Power & 3 x 660 Bara & Lalitpur TPPOther expected tenders 1 x 660 MW JITPL Angul, Jhabua Seoni, etc

Salient Feature:

• New series of HP & IP modules for supercritical parameters• Higher size LP module

247 ata Main Steam Pressure565 0C Main Steam Temperature593 0C Hot reheat Temperature

• Impulse tilted blade in HP & IP turbines

• Heat Shield at the inlet section

• Increase in wall/pipe thickness

• Material with improved properties for higher steam temperature

• Optimum flow path

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800MW Steam turbine

Salient features:• 4 cylinder turbine (2 LP’s)• New series of HP, IP & LP modules for super critical parameters

HP Turbine

LP Turbine 1 LP Turbine 2

IP Turbine

Condenser

Generator

Orders for Yermarus (2x800 MW), & Edlapur (1x800 MW), JV between KPCL and BHELOrder expected for NTPC 2 x 800 MW Gajmara TPP & Udangudi (2x800 MW), JV between TNEB and BHEL

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800MW Steam turbine:

General Arrangement

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CROSS SECTIONAL ARRANGEMENT OF 800 MW STEAM TURBINE

FOUR CYLINDER TURBINE

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CONSTRUCTIONAL FEATURES OF HP TURBINE FOR 800 MW

• SINGLE FLOW, DOUBLE SHELL• OUTER CASING BARREL TYPE IN TWO PIECES• INNER CASING AXIALLY SPLIT• MONO BLOCK DRUM TYPE ROTOR

Barrel in two pieces

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CONSTRUCTIONAL FEATURES OF IP TURBINE FOR 800 MW

• DOUBLE FLOW, DOUBLE SHELL CASING• MONO BLOCK DRUM TYPE ROTOR • STEAM ADMISSION IN L/H FROM BOTH SIDES• EXTRACTIONS CONNECTIONS IN LOWER HALF ONLY• VALVES BOLTED TO THE CASING IN LOWER HALF

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HPT FIRST STAGE

Diagonal Impulse Blading

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IP Turbine : HEAT SHIELD WITH VORTEX BORES

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• DOUBLE FLOW, DOUBLE SHELL• OUTER CASING FABRICATED , INNER CASING CASTINGS• MONO BLOCK ROTOR

CONSTRUCTIONAL FEATURES OF LP TURBINE FOR 800 MW

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SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

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INNER CASING IS INDEPENDENT OF OUTER CASING

INNER CASING RESTS ON OUTER CASING

660 MW500 MW

LP TURBINELP TURBINEDIFFERENCES IN CONSTRUCTIONAL FEATURES DIFFERENCES IN CONSTRUCTIONAL FEATURES

500 MW V/S 660 MW500 MW V/S 660 MW

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SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

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PUSH ROD ARRANGEMENT

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LP TURBINE INNER CASING SUPPORT DETAILS FOR 660 / 800 MW

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THROTTLE CONTROLLED GOVERNING WITH

HIGH PRESSURE ELECTRO HYDRAULIC COMPACT ACTUATORS (160 BAR)

GOVERNING

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NEW DESIGN(660 MW)

THROTTLE GOVERNINGHIGH PRESSURE ELECTRO HYDRAULIC GOVERNING(ACTUATORS WITH PRESSURE OF 160 BAR)

Turbine Governing

EXISTING DESIGN(500 MW) THROTTLE GOVERNINGELECTRO HYDRAULIC(WITH 32 BAR PRESSURE)

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Turbine Governing ADVANTAGES OF EHA BASED SYSTEM

• Simplified plant layout due to overall compact size

• Control oil piping reduced• Faster response due to state of art

electronic control and protection system • Better interconnection with other system• Ease of operation and maintenance

• Valve room is avoided

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Turbine GoverningEHA SYSTEM CONSISTS OF

* HYDRAULIC POWER SUPPLY UNIT* HPSU CONTROL UNIT* VALVES ACTUATORS* CONTROLLERS* PROTECTION SYSTEMS

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OVERHAULING

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SUMMARY

• Proven Supercritical technology in collaboration with M/s Siemens

• Steam Parameters up to 300 bar / 600°C / 620°C

• Modular Turbo set design to fit best customer needs

• High reliability & Availability

• Long Inspection intervals

• High efficiency by using modern CFD tools for flow path & blades

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Thank you for a Patient hearing…………